Pressurized Metal Container Preform Ironing Ratio Optimization
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Solution Overview
Problem
Current pressurized metal containers face challenges in maintaining shape stability and reducing metal usage while ensuring container integrity, particularly with high internal pressures, as traditional drawing and ironing processes are limited by an ironing ratio of up to 60% for steel and aluminum.
Innovation Solution
The process involves creating a pressurized metal container preform with an ironing ratio of 64% to 77% and a steel bottom thickness of 0.45 mm to 0.70 mm, allowing for reduced metal usage while maintaining shape stability and strength, using a drawing and ironing method that increases the efficiency of metal usage without compromising container properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If traditional drawing and ironing process is used with ironing ratio up to 60%, then container integrity and shape stability are maintained, but metal usage is excessive and cost is high
Solution Approach 1:
The patent applies parameter changes by increasing the ironing ratio from the traditional maximum of 60% to a new range of 64-77%, and by optimizing the bottom thickness to 0.45-0.70mm. This parameter change allows significant reduction in metal usage while maintaining container integrity and shape stability under high internal pressures
Solution Approach 2:
The patent applies local quality by differentiating the thickness of different parts of the container. The bottom is given a specific thickness range (0.45-0.70mm) that is optimized for its load-bearing function, while the body wall is thinne d through the high ironing ratio process. This localized optimization allows reduced overall metal usage while maintaining structural integrity where most needed
2Quantity of substance
If ironing ratio is increased to reduce metal usage, then material cost is reduced, but shape stability and container strength may be compromised
Solution Approach 1:
The patent resolves this contradiction by establishing specific parameter ranges: ironing ratio of 64-77% and bottom thickness of 0.45-0.70mm. These parameter changes enable reduced metal volume while maintaining shape stability, as the optimized bottom thickness compensates for the higher ironing ratio that thins the body wall
3Ease of manufacture
If bottom thickness is reduced to save material, then manufacturing cost decreases, but container strength under high pressure may be insufficient
Solution Approach 1:
The patent optimizes the bottom thickness to a specific range of 0.45-0.70mm, which represents a reduction from traditional thicker bottoms but maintains sufficient strength for high internal pressures. This parameter optimization reduces material cost while preserving the necessary container strength
Solution Approach 2:
The patent applies local quality by concentrating the necessary thickness in the bottom area (0.45-0.70mm) where it is most needed for structural support, while allowing the body wall to be thinner through the high ironing ratio process. This localized thickness distribution maintains strength where required while reducing overall material usage and cost
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the production of containers with optimal properties, such as reduced material usage and cost, while maintaining the structural integrity and shape stability necessary for handling, filling, and use, even with high internal pressures.
Implementation Method 1
The drawing and ironing process (such as the DWI process) has as an effect that the bottom has substantially the same thickness or gauge as the original disc, blank or sheet of metal. The ratio of the thickness of the wall of the container body wall over the thickness or gauge of the sheet of metal is called the ironing ratio
Data Source
Figure 1A~1E
Figure 2~4
AI summary
The invention relates to a pressurised metal container (11,17,24) preform (3), such as for an aerosol container (17) or beverage container (24), comprising a container body (12,18,25) unitary with a bottom (13,19,26), which container (11,17,24) has been made by ironing, wherein the ironing ratio is in the range of about 64% to 77%, and wherein the thickness of the bottom made of aluminum is in the range of about 0.50mm to 1.2mm, or the bottom made of steel is in the range of 0.30mm to 0.70mm, to a container (11,17,24) comprising such preform (3) and to methods for making same.